Systems and methods for dynamic sortation of objects

ABSTRACT

An automated shuttle sorter is disclosed that includes a carriage that is movable from a load position at which the carriage may be loaded, and at least two destination locations into which any contents of the carriage may be provided from the carriage.

PRIORITY

The present application is a continuation of U.S. patent applicationSer. No. 16/902,351, filed Jun. 16, 2020, now U.S. Pat. No. 11,400,491,issued Aug. 2, 2022, which claims priority to U.S. patent applicationSer. No. 15/241,779, filed Aug. 19, 2016, now U.S. Pat. No. 10,730,078,issued Aug. 4, 2020, which claims priority to U.S. Provisional PatentApplication Ser. No. 62/263,050 filed Dec. 4, 2015 as well as U.S.Provisional Patent Application Ser. No. 62/265,181 filed Dec. 9, 2015,the entire disclosures of which are-hereby incorporated by reference intheir entireties.

BACKGROUND

The invention generally relates to sortation systems, and relates inparticular to robotic and other sortation systems for sorting objects,where the sortation systems are intended to be used in dynamicenvironments requiring the systems to accommodate the processing of avariety of objects.

Current distribution center sorting systems, for example, generallyassume an inflexible sequence of operations whereby a disorganizedstream of input objects is first singulated into a single stream ofisolated objects presented one at a time to a scanner that identifiesthe object. An induction element (e.g., a conveyor, a tilt tray, ormanually movable bins) transport the objects to the desired destinationor further processing station, which may be a bin, a chute, a bag or aconveyor etc.

In typical parcel sortation systems, human workers or automated systemstypically retrieve parcels in an arrival order, and sort each parcel orobject into a collection bin based on a set of given heuristics. Forinstance, all objects of like type might go to a collection bin, or allobjects in a single customer order, or all objects destined for the sameshipping destination, etc. The human workers or automated systems arerequired to receive objects and to move each to their assignedcollection bin. If the number of different types of input (received)objects is large, a large number of collection bins is required.

Such a system has inherent inefficiencies as well as inflexibilitiessince the desired goal is to match incoming objects to assignedcollection bins. Such systems may require a large number of collectionbins (and therefore a large amount of physical space, large capitalcosts, and large operating costs) in part, because sorting all objectsto all destinations at once is not always most efficient.

In short, when automating sortation of objects, there are a few mainthings to consider: 1) the overall system throughput (parcels sorted perhour), 2) the number of diverts (i.e., number of discrete locations towhich an object can be routed), 3) the total area of sortation system(square feet), and 4) the annual costs to run the system (man-hours,electrical costs, cost of disposable components).

Current state-of-the-art sortation systems rely on human labor to someextent. Most solutions rely on a worker that is performing sortation, byscanning an object from an induction area (chute, table, etc.) andplacing the object in a staging location, conveyor, or collection bin.When a bin is full or the controlling software system decides that itneeds to be emptied, another worker empties the bin into a bag, box, orother container, and sends that container on to the next processingstep. Such a system has limits on throughput (i.e., how fast can humanworkers sort to or empty bins in this fashion) and on number of diverts(i.e., for a given bin size, only so many bins may be arranged to bewithin efficient reach of human workers).

Other partially automated sortation systems involve the use ofrecirculating conveyors and tilt trays, where the tilt trays receiveobjects by human sortation, and each tilt tray moves past a scanner.Each object is then scanned and moved to a pre-defined location assignedto the object. The tray then tilts to drop the object into the location.Further partially automated systems, such as the bomb-bay stylerecirculating conveyor, involve having trays open doors on the bottom ofeach tray at the time that the tray is positioned over a predefinedchute, and the object is then dropped from the tray into the chute.Again, the objects are scanned while in the tray, which assumes that anyidentifying code is visible to the scanner.

Such partially automated systems are lacking in key areas. As noted,these conveyors have discrete trays that can be loaded with an object;they then pass through scan tunnels that scan the object and associateit with the tray in which it is riding. When the tray passes the correctbin, a trigger mechanism causes the tray to dump the object into thebin. A drawback with such systems however, is that every divert requiresan actuator, which increases the mechanical complexity and the cost perdivert can be very high.

An alternative is to use human labor to increase the number of diverts,or collection bins, available in the system. This decreases systeminstallation costs, but increases the operating costs. Multiple cellsmay then work in parallel, effectively multiplying throughput linearlywhile keeping the number of expensive automated diverts at a minimum.Such diverts do not ID an object and cannot divert it to a particularspot, but rather they work with beam breaks or other sensors to seek toensure that indiscriminate bunches of objects get appropriatelydiverted. The lower cost of such diverts coupled with the low number ofdiverts keep the overall system divert cost low.

Unfortunately, these systems don't address the limitations to totalnumber of system bins. The system is simply diverting an equal share ofthe total objects to each parallel manual cell. Thus each parallelsortation cell must have all the same collection bins designations;otherwise an object might be delivered to a cell that does not have abin to which that object is mapped.

There remains a need for a more efficient and more cost effective objectsortation system that sorts objects of a variety of sizes and weightsinto appropriate collection bins or trays of fixed sizes, yet isefficient in handling objects of such varying sizes and weights.

SUMMARY

In accordance with an embodiment, the invention provides an automatedshuttle sorter that includes a carriage that is movable from a loadposition at which the carriage may be loaded, and at least twodestination locations into which any contents of the carriage may beprovided from the carriage.

In accordance with another embodiment, the invention provides asortation system that includes an automated carriage for receiving anobject at a load station from an object identification system. Theautomated carriage includes an automated transport system forreciprocally moving between at least two destination stations, and atransfer system for transferring the object from the automated carriageinto one of the at least two destination stations.

In accordance with a further embodiment, the invention provides a methodof sorting objects. The method includes the steps of acquiring an objectto be sorted from an input station, identifying the object, providingthe object to an automated carriage that is reciprocally movable betweenat least two destination stations, and moving the object to one of theat least two destination stations.

BRIEF DESCRIPTION OF THE DRAWINGS

The following description may be further understood with reference tothe accompanying drawings in which:

FIG. 1 shows an illustrative diagrammatic view of a sortation system inaccordance with an embodiment of the invention;

FIG. 2 shows an illustrative diagrammatic view of a carriage for use inthe sortation system of FIG. 1 ;

FIGS. 3A-3C show illustrative diagrammatic views of the carriage of FIG.2 at different stages of movement;

FIG. 4 shows an illustrative flowchart showing processing steps duringoperation of a system in accordance with an embodiment of the invention;

FIG. 5 shows an illustrative diagrammatic view of a sortation system inaccordance with another embodiment of the invention;

FIGS. 6 and 7 show illustrative diagrammatic views of a portion of thesystem of FIG. 5 ;

FIG. 8 shows an illustrative diagrammatic view of a sortation system inaccordance with a further embodiment of the invention that includes twocarriages;

FIG. 9 shows an illustrative diagrammatic view of a sortation system inaccordance with a further embodiment of the invention that includes fourcarriages; and

FIG. 10 shows an illustrative diagrammatic view of a sortation system inaccordance with a further embodiment of the invention that includeseight carriages.

The drawings are shown for illustrative purposes only.

DETAILED DESCRIPTION

In accordance with various embodiments, the invention provides aninherently more flexible object sortation system in which objects may beselected in a most advantageous order, and the sortation of thoseobjects may take advantage of dynamically varying correspondence betweenthe sorter outputs and the ultimate object destinations. The inventionfurther provides a highly efficient and readily scalable system forproviding the transport and distribution of objects.

Systems and methods of the present invention are well suited toapplications in current sortation systems that receive objects in adisorganized stream and are required to sort the objects into sortedstreams. Such systems recognize that reading information on an objectmay sometimes be challenging, so that once an object is scanned, it isimportant to keep the information associated with the object. Theacquisition of objects from disorganized jumbles is challenging, andonce an object is acquired, it is important to keep the object separatedfrom other objects. Further, the transport and conveying systems havelimited flexibility, typically following a single track that passesevery possible destination.

In accordance with certain embodiments, the invention provides systemsand methods that upend basic assumptions of current sortation systems,with improvements in each of the challenges identified above. Thesystems, in some embodiments, provide improved transport anddistribution, and further provide for the identification of the entireobject's shape and disposition, reducing or eliminating the need to keepthe object separate from others. The use of robotic manipulatorsimproves the reliability and economy of acquiring objects, even when ina jumble with other objects, reducing the need to maintain separation ofobjects. The systems, in further embodiments, provide improved transportand conveyor systems, and provide learning algorithms in particular,that allow dynamically changing patterns of object handling, withresulting efficiencies in the sortation process, lower spacerequirements, lower demand for manual operations, and as a consequence,lower capital and operating costs for the entire system.

FIG. 1 , for example, shows a system 10 in accordance with an embodimentof the present invention that includes a sorting station 12 that is fedby a common input conveyor 16. An output track 18 carries an outputcarriage 50 to bins 22, 24, 26, 28, 32, 34, 36 and 38. The carriage 50brings items to a dynamically assigned bin. The sorting station 12 mayalso include a scanner 40 that permits an object to be scanned whilebeing held by an end effector of a robotic system 20. A centralcontroller 44 communicates with the robotic system 20 and scanner 40 toprovide input regarding the assignment of objects to a bin as discussedin more detail below. An additional scanner 46 may be employed toprovide the sorting stations with advance information regarding objects48 that are being provided on the input conveyor 16. The system may alsoinclude further sorting stations, e.g., 14, that may also include ascanner 42 that permits an object to be scanned while being held by anend effector of a robotic system 30. A central controller 44communicates with the robotic system 30 and scanner 42 to provide inputregarding the assignment of objects to a bin as discussed in more detailbelow.

During use, each sorting station 12, 14 may either select an object andthen identify the selected object by a detection device on thearticulated arm, or may use the articulated arm to hold the object infront of a scanner, or may place the object into a scanner as discussedbelow, or may first identify an object prior to selection, and thengrasp the identified object. In any event, the system then assigns a binto the object if a new bin is available and the object is not yetassigned a bin at that sorting station. What is significant is that thesorting station is not pre-assigned a large set of collection binsassigned to all possible objects that may appear in the input path.Further, the central controller may employ a wide variety of heuristicsthat may further shape the process of dynamically assigning objects tocollection bins as discussed in more detail below. The input conveyormay be also provided as a loop conveyor on which objects pass bymultiple sorting stations, or the input conveyor may be provided asmultiple conveyors on which objects pass by multiple sorting stations.The invention provides, therefore, examples of sortation systems thatinvolve moving infeed objects directly to a buffer, without humanintervention. The buffer holds the objects, possibly in a disorganizedjumble, where they may be accessed by one of several sorters. Theperception system may read labels when they are visible, but may alsouse more general machine vision algorithms to identify object class andshape, and to track objects as they are circulated. The sorters acquireobjects from the buffer. If needed, they use their own perceptionsystems to read labels not previously read. They may move objects to anyof several outputs, including the possibility of placing an object backon the buffer, either for later handling or for handling by a differentsorter.

Systems of various embodiments provide numerous advantages because ofthe inherent dynamic flexibility. The flexible correspondence betweensorter outputs and destinations provides that there may be fewer sorteroutputs than destinations, so the entire system may require less space.The flexible correspondence between sorter outputs and destinations alsoprovides that the system may choose the most efficient order in which tohandle objects, in a way that varies with the particular mix of objectsand downstream demand. The system is also easily scalable, by addingsorters, and more robust since the failure of a single sorter might behandled dynamically without even stopping the system. It should bepossible for sorters to exercise discretion in the order of objects,favoring objects that need to be handled quickly, or favoring objectsfor which the given sorter may have a specialized gripper.

The system may also employ a flexible destination stage, including aprocess for dynamically changing the correspondence of sorter outputsand system destinations using a switch based on heuristics from thesortation process. The system may dynamically map sorter outputs tosystem destinations based on long-term historical usage trends andstatistics, or items already processed, or current contents of otherdynamically allocated sorter outputs, or average, minimum or maximumtime-to-sort associated with each sorter output, or physicalcharacteristics of the items sorted, or a priori information, or knownfuture deliveries, or location within a facility, including the physicallocation relative to other allocated sorter outputs (e.g., above,beside, on or nearby), or incoming shipments, as well as knowing whatitems are currently upstream of the sortation process and combinationsof the above. Further, systems of embodiments of the invention providethat information regarding correspondence between sorter outputs tosystem destinations may be provided to an automated system for sorting.

By making use of heuristics, the mapping of sorter outputs to systemdestinations can be improved substantially over traditional fixedallocation. Destinations may be assigned on the fly, reducing wastedspace from unused sorter outputs and decreasing the time it takes toprocess incoming objects. Long-term historic trends may be used toallocate sorter outputs when the next incoming group of objects iseither in-part or entirely unknown. Historical usage patterns provideinsight into when objects bound for certain destinations can be expectedto arrive, the number of objects bound for each destination expected forany given time, and the probable physical properties of these incomingobjects.

In addition to trends pertaining to incoming objects, historical trendsprovide information on the speed at which objects can be sorted intooutputs, and the rate at which outputs are transferred to systemdestinations. These factors allow sorter outputs to be allocatedprobabilistically until a deterministic understanding of incomingobjects is achieved.

In addition to historic trends, an understanding of the current state ofthe system is used to ensure that there is an appropriate amount ofspace allocated for those objects that are expected to arrive. Whencombined with the knowledge of those objects that have already beensorted, the correspondence of sorter outputs to system destinations cantypically be allocated deterministically. A knowledge of those objectsalready processed and the contents of current sorter outputs allows thesystem to optionally remap the sorter outputs once they have beenemptied of their contents. In the case that there aren't enough sorteroutputs, this knowledge also allows the system to specify which sorteroutputs should be emptied such that they can quickly be reallocated tonew system destinations.

A further consideration when dynamically allocating sorter outputs is totake into account the physical characteristics of the packages and thefacility. If a certain destination is expected to receive larger,unwieldy objects, then an appropriately-sized sorter output can beallocated. If a particular system destination will require more than asingle sorter output, then two adjacent outputs can be allocated withthe same destination in order to facilitate human intervention.

A method is also presented for displaying the sorter output—systemdestination correspondence information next to the destinations. Thisallows human workers interacting with the system to understand how andwhen to properly empty the destinations. In addition, critical toautonomous sortation is the ability to send these destinationallocations to a sortation system without human intervention. Thisallows for the construction of fully-streamlined sortation systemsoftware.

The carriage system for placement at destination locations is alsoefficient and scalable. As shown in FIG. 2 , for example, the carriage50 includes a load bed 52 that is pivotally mounted on a carrier 54 (asgenerally indicated at A). The carrier 54 is slidably mounted on thetrack 18 (as generally indicated at B). The movement of the carriage maybe provided by any of a variety of power sources, such as electriccharge via an electric track, or by pneumatics or a belt drive thatdrive the carriage along the track in both directions with good speedand accuracy. Similarly, the tipping of the carriage may be provided byany of a variety of power sources such as electric charge (e.g., usingreverse direction solenoids), or by pneumatics that tip the carriage ineither direction (transverse to the direction of the track) as desired.

For example, FIGS. 3A-3C show the carriage 50 conveying an object 80within the load bed 52 of the carriage 50 from a first location (FIG.3A) to a destination location (FIG. 3B), whereupon the load bed 52 istipped (FIG. 3C), causing the object 80 to fall into the a desireddestination location 24 among a plurality of other destination locations22, 26, 32, 34, 36.

In accordance with certain embodiments therefore, systems of theinvention may employ carriages that shuttle back and forth along shuttledirections. Such systems may rely on a pre-sortation step, where anobject is sorted first to the correct sortation station, and once there,it is sorted into the proper collection bin. In this fashion, differentstations can have different collection bin mappings, allowing the totalnumber of system bins to be multiplied by the number of parallelsortation stations operating. Such pre-sortation steps however, must beeither complicated and expensive automated systems, or must rely on yetmore human work; either way adds cost which raises the overall cost perdivert of the system to unacceptably high levels. The invention providesa new approach to object sortation that yields a large (and veryflexible and scalable) number of total collection bins, very low divertcosts per bin, throughput as high as that of a manual system, and a farsmaller need for manual labor to operate.

FIG. 4 shows a flowchart of the operation of a system in accordance withan embodiment of the present invention. The process begins (step 100)and the articulated arm, or another object reception device, receives anew object (step 102). The system then identifies the new object (step104) by any of an overhead scanner 46, or a scanner system 40, 42, or bya drop scanner as discussed below, etc. The system then determineswhether any location at the station has yet been assigned to the newobject (step 106). If so, the system then places the object at thatlocation (step 118). If not, the system then determines whether a nextlocation is available (Step 108). If not, the system may (either with orwithout input from a human) determine whether to retry identifying theobject (step 112). If so, then the system would return the object to theinput stream (step 114) to be again received at a later time (step 102).If not, the system would place the object in a manual sorting area forsortation by a human (step 116). If a next location is available (step108), the system then assigns a next location to the object (step 110),and the object is then placed in that location (step 118). If a locationhad already been assigned to the object (step 106), then the system theobject is placed in that location (step 118). The number of objects atthe location is then updated (step 120), and if the location is thenfull (step 122), the system identifies that the location is ready forfurther processing (step 126). If not, the system then determineswhether (based on prior knowledge and/or heuristics), whether thelocation is likely to receive a further object (step 124). If so, thesystem identifies that the location is ready for further processing(step 126). If not, the system returns to receiving a new object (step102). The further processing may, for example include collecting theitems at the location in a single bag for transport to shipping to ageographic area.

FIG. 5 shows, for example, a shuttle system 200 that includes a carriage50 on a track 18 that accesses locations 202, 204, 206, 208, 210, 212,214, 216, 222, 224, 226, 228, 230, 232, 234 and 236. Each location mayinclude chute walls 240 for guiding the objects, and bins 242 forreceiving the objects. Generally, objects are serially loaded into thecarriage 50 at a first end 248, and the carriage 50 shuttles the objectsto the assigned bins. The bins 242 may be provided on drawers 244 thatslide out from the system 200, wherein the bins for locations 212 and232 are shown pulled out. Each drawer 244 may include lights 246 thatbecome illuminated when the system identifies that a bin is ready forfurther processing. As shown in FIG. 9 , the light associated with thebin at location 212 is shown lit because the bin has been identified asbeing full. A hand-held printer (or printer/scanner) 250 may be inwireless communication with the central controller 44, and may print outa label 252 specifically identifying the contents of the bin that isbeing emptied for further processing. In certain embodiments, forexample, the bin may include a bag that is sealed and labeled by a label252 when pulled from the drawer. As shown in FIGS. 6 and 7 , when thecarriage is tipped on the track 18, the carriage 18 does not enter intothe area defined by the chute walls. This permits the carriage 18 tobegin its travel back to the first end 248 as soon as the object isejected from the carriage.

FIG. 8 shows a shuttle sortation system 300 that includes two shuttlesystems 200 of FIG. 5 , each of which includes a carriage 50 on a track18 that provides objects to bins 242. The system 300 also includes anarticulated arm 302 with an end effector 304, an input area 306 in whichobjects are presented for sortation, an overhead camera 308 foridentifying objects to be sorted, and a receiving conveyor 310 forreceiving objects to be sorted from any of a human worker, anotherconveyor, or an input pan. The system also includes a non-sortableoutput chute 312 that leads to a non-sortable output bin 314 forproviding objects that the system either could not identify or could notsort for any other reason (e.g., could not grasp or pick up).

In addition to the overhead camera 308, the system also includes a dropscanner 316 that includes an open top and open bottom, and a pluralityof cameras positioned within the unit 316 that are aimed at the top, midand lower central regions of the interior of the unit 316, as disclosed,for example, in U.S. Provisional Patent Application Ser. No. 62/269,640filed Dec. 18, 2015 and U.S. patent application Ser. No. 15/228,692,filed Aug. 4, 2016, the disclosures of which are hereby incorporated byreference in their entireties. The plurality of cameras take images ofan object when it is dropped by the end effector 304 through the unit316. The unit 316 may also include lights within the unit 316, and oneor more sensors (e.g., laser sensors) at the top of the unit 316 thatdetect when an object is dropped into the unit 316. The plurality ofcameras are designed to collect a plurality of images of each objectfrom multiple views (ideally all possible views) to aid in identifyingor confirming the identity of the dropped object.

The dropped object then falls into a first carriage 318 that is providedon a track 320 on which the conveyor 318 may be moved automaticallybetween a first sortation stage 322 and a second sortation stage 324 oneither side of the area in which the object was dropped. The firstcarriage 318 is also provided with actuators that may selectively causethe carriage to tip on either side of the track 320 to dump its contentsinto either the carriage 50 at sortation stage 322 or sortation stage324, similar to the operation of the carriage 50 discussed above withreference to FIGS. 1-7 . The first sortation stage 322 includes acarriage 50 that may receive objects from the carriage 318, and whichtravels along a track between two rows of collection bins into whichobjects may be dumped along guide walls 240, and the second sortationstage 324 includes a carriage 50 that may receive objects from thecarriage 318, and which travels along a track between two rows ofcollection bins into which objects may be dumped along guide walls 240.

The system of FIG. 8 shows a system with two shuttle sorters. When anobject is picked from the infeed conveyor, it is dropped onto the firstshuttle sorter 318. That shuttle sorter carries the object to one of twoshuttle systems 200, drops the object in the carrier for that system,and then moves back to home. Each of the carriers for systems 200 mayalso include a carriage guide 430 (as shown in FIG. 9 ) that guidesobjects into a carriage 50 but does not move with the carriage. Due tothe limited travel, this back and forth operation may be performed inthe time it takes the articulated arm to pick another object (assumingthe articulated arm is picking objects at approximately a human rate ofthroughput).

The shuttle sorter system therefore includes an object carriage on amotorized linear slide that travels above a double row of collectionbins. The carriage is loaded with an object and then moves along thelinear slide until it has reached the collection bin where the objectbelongs; it then uses rotational actuation to eject the object to oneside or the other, where it falls into one of the two collection bins atthat location. The carrier then returns to the home position to awaitanother object.

In the concept as shown, each system 200 is limited to 8 collection binslong, for 16 total collection bins per wing. The length of collectionbins traveled by the linear carriage should be balanced with otherthroughput factors in the system. Given achievable speeds for beltdriven linear actuators, distances, and picking speed of the articulatedarm, this length of 8 collection bins is a reasonable length that doesnot adversely limit system throughput (i.e., the articulated arm doesnot have to wait for a carriage to return to home before picking anotherobject). At this 8×2 or 16 collection bin count, each system 200 has adivert cost far less per intelligent divert for currently fieldedsolutions, as discussed above.

Systems in the prior art also do not use back and forth style sortationbecause the shuttle can only handle one item at a time, and the shuttleneeds to return to its home position after each sort. In this system,this concern is alleviated in three ways: 1) multiple systems 200 areused in parallel, 2) frequent destinations are assigned to collectionbins closer to the shuttle's home position, thereby reducing the averagecycle time of the shuttle, and 3) mapping of objects to collection binsis dynamic and under the control of the system as discussed above withreference to the system of FIGS. 1-7 .

Systems of the invention are therefore, highly scalable. FIG. 9 , forexample, shows a system 400 that includes four shuttle systems 200 ofFIG. 5 , each of which includes a carriage 50 on a track 18 thatprovides objects to bins 242. The system 400 also includes anarticulated arm 402 with an end effector 404, an input area 406 in whichobjects are presented for sortation, a primary camera 408 foridentifying objects to be sorted, and a receiving conveyor 410 forreceiving objects to be sorted from any of a human worker, anotherconveyor, or an input pan. The system also includes a non-sortableoutput chute 412 that leads to a non-sortable output bin 414 forproviding objects that the system either could not identify or could notsort for any other reason (e.g., could not grasp or pick up).

Again, in addition to the overhead camera 408, the system also includesa drop scanner unit 416, which includes an open top and open bottom, anda plurality of cameras positioned within the unit 416 that are aimed atthe top, mid and lower central regions of the interior of the unit 416,as discussed above with reference to drop scanner unit 316 of FIG. 8 .The dropped object then falls into a carriage 418 that is provided on atrack 420 on which the conveyor 418 may be moved automatically between afirst sortation stage 422, a second sortation stage 424, a thirdsortation stage 426, and a fourth sortation stage 428. Again, thecarriage 418 is also provided with actuators (e.g., electric orpneumatic) that may selectively cause the carriage to tip on either sideof the track 420 to dump its contents into the carriage 50 at any ofsortation stages 422, 424, 426 or 428, similar to the operation of thecarriage 50 discussed above with reference to FIGS. 1-8 .

The system 400 therefore includes 64 total collection bins. This systemmay be further scaled to add more collection bins. The first shuttlesorter (that transfers objects from the picking robot to the systems200) may also be lengthened to accommodate 4 shuttle systems 200 beforesystem throughput is adversely affected.

In particular, the system may be further expanded by again doubling thenumber of systems 200. This requires the addition of another shuttlesorter that takes the object from the picking robot and delivers it toone of the 4 systems 200. This keeps the shuttle sort back and forthtravel time from adversely effecting overall system throughput. Such asystem is shown in FIG. 10 . FIG. 10 shows a system 500 that includeseight shuttle systems 200 of FIG. 9 , each of which includes a carriage50 on a track 18 that provides objects to bins 242. The system 500 alsoincludes an articulated arm 502 with an end effector 504, an input area506 in which objects are presented for sortation, and a receivingconveyor 410 for receiving objects to be sorted from any of a humanworker, another conveyor, or an input pan. The system also includes anon-sortable output chute 512 that leads to a non-sortable output binfor providing objects that the system either could not identify or couldnot sort for any other reason (e.g., could not grasp or pick up).

Again, the system 500 also includes a drop scanner 516, which includesan open top and open bottom, and a plurality of cameras positionedwithin the scanner 516 that are aimed at the top, mid and lower centralregions of the interior of the scanner 516, as discussed above withreference to drop scanner 316 of FIG. 10 . The dropped object then fallsinto one of two carriages 518, 520 that are provided on a track 522 onwhich the carriages 518, 520 may be moved automatically between a firstsortation stage 524, a second sortation stage 526, a third sortationstage 528, a fourth sortation stage 530, a fifth sortation stage 532, asixth sortation stage 534, a seventh sortation stage 536 and an eighthsortation stage 538. Again, the carriages 518, 520 are also providedwith pneumatic actuators that may selectively cause the carriage to tipon either side of the track 522 to dump its contents into the carriage50 at any of sortation stages 524-538, similar to the operation of thecarriage 50 discussed above with reference to FIGS. 1-9 . The system 500therefore includes 64 total collection bins.

In each of the systems 300, 400 and 500, the carriages 318, 418, 518,520 are able to travel along its track in a direction far enough toreach both the input conveyor as well as the non-sortable output chute.This provides that the system may elect to send an object in the firstcarriage to either the input conveyor to be re-processed, or to thenon-sortable output chute if the object is not sortable.

The system also provides, in each embodiment, dynamic collection binallocation as discussed above. In typical human manned systems,collection bins are statically associated (to destinations, next stopfacilities, customers, etc.) and don't change frequently; this is sothat efficiency benefits, may be gained by humans learning theassociation and cubby locations. In the systems discussed above, no suchconstraints exist, since the system is placing all of the objects incollection bins, and it always has comprehensive knowledge of whichobjects are in the system, which are in each bin, etc. The systems alsohave knowledge of all historical sortation activity, meaning thathistorical trends can be used to make even smarter choices aboutcollection bin allocation.

If, for example, the historical data suggests that two of the collectionbins in this system get the most objects in each sort cycle, then thesystem will allocate one of these bins to the first system 200 (wing),and one to the second, thus ensuring that all the high volume bins arenot on one wing creating a bottleneck. The system may also allocate binsclose to the beginning of the wing, thereby ensuring minimum cycle timesfor the busiest collection bins. Further, if the system needs an emptybin, it can signal to a human operator to come and empty a given bin,allowing that bin to be used as soon as it is emptied. These strategiesensure that the cycle time of the shuttle sort wings does not impactoverall system throughput.

Additionally, the system may also allocate and group objects so as tomaximize any other arbitrary cost function. Such a sortation system isalmost always a small part of a large system, usually extending acrossmultiple facilities around the state, country, or world. As a part ofsuch a large network, the performance of this system inevitably hasimpacts on costs elsewhere in the network. By understanding theseimpacts, the system presented here can allocate objects to collectionbins in order to minimize cost impact elsewhere in the macro network.

In this system concept, additional articulated arms (robots) may also beadded to each of the concepts to scale throughput for the system. Byadding robots and shuttle sort wings, and tuning shuttle sorter speedsand robot picking/scanning speeds, a wide range of overall systemthroughputs and collection bin counts are possible using the same basicarchitecture.

For further scaling 8 wings fed by one pick/scan station may be amaximum for certain applications. To scale a maximum number of bins anda maximum throughput beyond this, multiple of these stations can beparallelized and fed by manual or automated means, just as manual sortcells are fed in concepts discussed in the prior art. This allows forcontinued linear scaling of throughput, as well as for greater numbersof collection bins, since the system can now dynamically allocatebetween all the bins in all the wings in all of the parallel cells.

Those skilled in the art will appreciate that numerous modifications andvariations may be made to the above disclosed embodiments withoutdeparting from the spirit and scope of the present invention.

What is claimed is:
 1. An object processing system comprising: aprogrammable motion device with an end-effector for grasping at an inputarea a selected object, and for moving the selected object; a carriagewith a load bed for receiving the selected object thereon from theend-effector of the programmable motion device, said carriage beingmovably mounted at a carriage elevation on a track system for movementof the carriage at the carriage elevation; a plurality of destinationlocations with output bins with open tops provided at a destinationlocation elevation that is lower than the carriage elevation; and anactuation system for causing the carriage to discharge the selectedobject from the load bed and drop the selected object into a selectedoutput bin of a selected destination location of the plurality ofdestination locations, wherein the carriage is driven in a firstdirection to move along the track system from a first location towardsthe selected destination location and is driven in a second directionthat is different than the first direction to move along the tracksystem towards the first location from the selected destination locationto receive a next selected object from the programmable motion device atthe first location.
 2. The object processing system as claimed in claim1, wherein the end-effector includes a vacuum cup for grasping theselected object.
 3. The object processing system as claimed in claim 2,wherein the selected object is dropped from the vacuum cup into the loadbed of the carriage.
 4. The object processing system as claimed in claim1, wherein the actuation system tips the load bed of the carriage todischarge the selected object from the load bed and drop the selectedobject into the selected output bin.
 5. The object processing system asclaimed in claim 1, wherein the plurality of destination locations isprovided as an array of destination locations arranged underneath thetrack system.
 6. The object processing system as claimed in claim 5,wherein the selected output bin of the selected destination location isprovided on a pull-out drawer.
 7. The object processing system asclaimed in claim 6, wherein the pull-out drawer includes at least oneadditional output bin in addition to the selected output bin.
 8. Theobject processing system as claimed in claim 1, wherein the carriagechanges from being driven in the first direction to the second directionafter the selected object is dropped into the selected output bin.
 9. Anobject processing system comprising: a programmable motion device with avacuum end-effector for grasping at an input area a selected objectamong a plurality of objects, and for moving the selected object to aprocessing area; a carriage with a load bed for receiving the selectedobject thereon from the vacuum end-effector of the programmable motiondevice, said carriage being movably mounted at a carriage elevation on atrack system for movement of the carriage at the carriage elevationwithin the processing area, wherein the carriage is driven in a firstdirection to move along the track system to deliver the selected objectand is driven in a second direction that is different than the firstdirection to move along the track system to receive a next selectedobject from the programmable motion device; a plurality of destinationlocations provided below the track system at a destination locationelevation that is lower than the carriage elevation; and an actuationsystem for causing the carriage to tip such that the selected object isdischarged from the load bed and dropped into a selected destinationlocation of the plurality of destination locations below the tracksystem, wherein the selected destination location is defined betweenchute walls and the carriage is tipped to drop the object into theselected destination location via the chute walls.
 10. The objectprocessing system as claimed in claim 9, wherein the end-effectorincludes a vacuum cup for grasping the selected object.
 11. The objectprocessing system as claimed in claim 10, wherein the selected object isdropped from the vacuum cup into the load bed of the carriage.
 12. Theobject processing system as claimed in claim 9, wherein the plurality ofdestination locations is provided as an array of destination locationsarranged underneath the track system.
 13. The object processing systemas claimed in claim 12, wherein the selected destination locationincludes a selected output bin that is provided on a pull-out drawer.14. The object processing system as claimed in claim 13, wherein thepull-out drawer includes at least one additional output bin in additionto the selected output bin.
 15. The object processing system as claimedin claim 9, wherein the carriage changes from being driven in the firstdirection to the second direction after the selected object is droppedinto the selected destination location.
 16. A method of processingobjects, said method comprising: grasping a selected object with anend-effector of a programmable motion device; moving the selected objectwith the end-effector to a processing area; dropping the selected objectfrom the end-effector to a load bed of a carriage for receiving theselected object; driving the carriage at a carriage elevation on a tracksystem in a first direction to move from a home location of theprocessing area to a selected destination location of a plurality ofdestination locations within the processing area, wherein the pluralityof processing locations are provided below the track system; droppingthe selected object from the carriage into a selected output bin at theselected destination location by tipping the carriage in a directiontransverse to the track system; and driving the carriage in a seconddirection that is different than the first direction to move along thetrack system from the selected destination location back to the homelocation of the processing area to receive a next selected object fromthe programmable motion device.
 17. The method as claimed in claim 16,wherein the end-effector includes a vacuum cup for grasping the selectedobject.
 18. The method as claimed in claim 17, wherein the selectedobject is dropped from the vacuum cup into the load bed of the carriage.19. The method as claimed in claim 16, wherein the plurality ofdestination locations is provided as an array of destination locationsarranged underneath the track system.
 20. The method as claimed in claim19, wherein the method further includes removing the selected output binfrom the processing area on a pull-out drawer.
 21. The method as claimedin claim 20, wherein the pull-out drawer includes at least oneadditional output bin in addition to the selected output bin.
 22. Themethod as claimed in claim 16, wherein the carriage changes from beingdriven in the first direction to the second direction after the selectedobject is dropped into the selected output bin.